Polaris Sportsman 500 EFI - User Manual

Polaris Sportsman 500 EFI

Polaris Sportsman 500 EFI – User Manual, read for free online in PDF format. We hope this helps you resolve any issues you may have. If you have further questions, please contact us through the contact form.

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Table of Contents:

  • Page 3 – to the owner’s manual on the next page. If you cannot locate this card,; The engine exhaust from this; WARNING
  • Page 4 – WELCOME; RANGER
  • Page 6 – TABLE OF CONTENTS
  • Page 8 – VEHICLE IDENTIFICATION NUMBERS; Record your ATV’s identification numbers and key number in the
  • Page 9 – SAFETY; Safety Decals and Locations; ATV, always read and follow the instructions of the decals
  • Page 10 – ATTENTION
  • Page 11 – NO STEP
  • Page 13 – Safe Riding Gear
  • Page 14 – Operator Safety; vehicle handles differently than other vehicles, such as; Age Restrictions
  • Page 15 – are used. Become familiar with their meanings before reading the; safety alert symbol; safety alert warning; safety alert caution; CAUTION; caution
  • Page 16 – Serious injury or death can result if you do not follow these; Take a training
  • Page 18 – FOR MORE INFORMATION ABOUT ATV SAFETY, call the Con-; Equipment Modifications; The addition of certain accessories, including (but not limited
  • Page 19 – not know how to operate the ATV properly in different situations; abilities, or judgment needed to operate an ATV safely and could
  • Page 22 – could seriously affect operator; visibility and operating conditions, and your experience.
  • Page 23 – the chance of an accident,; schedules described in the owner’s manual.
  • Page 25 – caution when operating on
  • Page 28 – turning as hills could cause
  • Page 29 – or improperly dismounting
  • Page 30 – trees when possible. If unavoidable, use extreme caution and; caution to reduce the chance of skidding or sliding out of control.; people behind the ATV. When it’s safe to proceed, back slowly.
  • Page 31 – unavoidable to enter water that exceeds the recommended
  • Page 32 – accessories. All parts and accessories added to the vehicle must
  • Page 34 – CONTROLS; Engine Electrical Switches; OFF
  • Page 35 – Throttle Lever; Engine speed and vehicle movement
  • Page 36 – Light Switches; ON; Brake Lever
  • Page 37 – Master Cylinder; eye
  • Page 38 – Parking Brake; Operating the ATV while the parking brake is engaged could; Setting the Parking Brake
  • Page 39 – Auxiliary Brake; Aggressively applying the auxiliary brake when backing down a; reduce; Brake Fluid Level
  • Page 40 – Fuel Tank
  • Page 41 – Automatic Transmission Gear Selector; Shifting gears with the engine speed above idle or while the; PARK and lock the parking brake.; Belt Life
  • Page 42 – FEATURES; The override switch allows activation of AWD in reverse if the; Engaging Front Gearcase; Switching to AWD while the rear wheels are spinning may cause
  • Page 43 – Instrument Cluster; speed from the right front wheel. The instrument cluster measures; To prevent damage, wash the ATV by hand or with a garden hose
  • Page 44 – Rider Information Center; If the instrument cluster fails to illuminate, a battery; Engine Hour Display Indicator
  • Page 45 – mode
  • Page 46 – Diagnostic Mode; Any movement of the tires will also take the machine out of
  • Page 47 – If you scroll past the intended number, hold the button down
  • Page 48 – Special EFI Diagnostic Mode
  • Page 49 – OPERATION; Fuel Safety
  • Page 50 – Excessive heat build-up during the first three hours of operation; Engine and Drivetrain Break-in
  • Page 51 – If a proper inspection is not done before each use, severe injury
  • Page 52 – Starting the Engine; Cold Weather Operation
  • Page 53 – Driving Safely; Hauling Cargo; Your ATV has been designed to carry or tow a certain amount of load.; Use low forward gear when hauling or towing heavy cargo to extend
  • Page 55 – Driving Procedures
  • Page 56 – Making Turns; Practice making turns at slow speeds before attempting to; Turning at sharp angles or at excessive speeds can result in
  • Page 57 – Driving on Slippery Surfaces
  • Page 58 – Driving Uphill; include quick dismounting of the vehicle.; terrain. Improper procedure could cause loss of control or
  • Page 59 – Sidehilling; control or vehicle overturn, resulting in severe injury or death.; hill while keeping your feet on the footrests.; If the vehicle begins to tip, quickly turn the front wheel
  • Page 60 – Driving Downhill; slightly; Excessive speed can cause loss of control and lead to serious
  • Page 61 – Turning Around on a Hill; vehicle is pointing straight uphill.
  • Page 62 – Driving Through Water; critical
  • Page 63 – Driving Over Obstacles; Be constantly alert for hazards such as logs, rocks and low hanging; Severe injury or death can result if your vehicle comes in contact
  • Page 64 – Driving in Reverse; apply the brakes
  • Page 65 – Parking on an Incline; Avoid parking on an incline if possible. If it’s unavoidable, follow
  • Page 66 – EMISSION CONTROL SYSTEMS; Noise Emission Control System
  • Page 67 – MAINTENANCE AND LUBRICATION; Periodic Maintenance Chart; Service and adjustments are critical. If you’re not familiar; Severe Use Definition
  • Page 68 – Maintenance Chart Key; not void the emissions warranty but may affect emissions.); Improperly performing the procedures marked with a
  • Page 72 – Lubrication Guide; The a-arms and lower control arms are lubricated at the; Lubrication Guide Key; More often under severe use
  • Page 73 – Premium 4 Synthetic Lubricant; See page 107 for the part numbers of Polaris products.; SH; Mixing brands or using a non-recommended oil may cause
  • Page 74 – Oil Level; A rising oil level between checks in cool weather driving can
  • Page 75 – Oil and Filter Change; The sealing surfaces on the drain plug and the oil tank
  • Page 76 – Oil Change; The sealing surfaces on; Prime the oil pump using the procedure on page 74.
  • Page 77 – Oil Pump Priming; If you do not hear
  • Page 78 – Transmission Oil; Oil Check
  • Page 79 – The transmission drain plug (2) is located on the right side of the
  • Page 80 – Front Gearcase Oil; Premium Demand Drive Hub Fluid
  • Page 81 – Engine Cooling System; Radiator Coolant Level
  • Page 82 – Coolant Level; Some coolant level drop on new machines is normal, as the
  • Page 83 – Brakes; The front and rear brakes are hydraulic disc brakes, activated by
  • Page 84 – damage and looseness.; Pads should be changed; main brake system. Should the main system fail, the rear brake can be; Since this is a rear brake only, it will not be as effective as
  • Page 85 – Steering Assembly
  • Page 86 – Side Panel Removal; motion, pull the panel outward to disengage the side panel from the; Footwell Removal; on the bottom of the footwell.
  • Page 87 – Operating your ATV with worn tires, improperly inflated tires,; Tire Tread Depth
  • Page 88 – Wheel Installation; Improperly installed wheels can adversely affect tire wear and; Cast Aluminum; Wheel Nut Torque Specifications; Check the wheel nut torques occasionally and when they’ve been; Nut Type
  • Page 89 – Filter Systems; Air Filter Service; It’s not necessary to remove the lower hose from the engine.; Operation of your vehicle without a breather filter can cause
  • Page 90 – Lights; When servicing a halogen lamp, don’t touch the lamp with bare; Poor lighting while driving can result in severe injury or death.; Headlight Lamp Replacement; Remove the two screws on the lower front corners of the headlight; Make sure the tab on the lamp locates properly in the
  • Page 91 – High Beam Adjustment; Include rider weight on the seat when measuring.; Low Beam Adjustment
  • Page 92 – Headlight Housing Replacement; The distance from the; Adjust the headlight aim by
  • Page 93 – Lower Headlamp Removal / Installation
  • Page 94 – Spark Plugs; Using non-recommended spark plugs can result in serious engine; A hot exhaust system and engine can cause serious burns. Wear; Spark Plug Removal and Replacement
  • Page 95 – Vehicle Immersion; Check the air box for any water and dry it if water is present.
  • Page 96 – Spark Arrestor; Failure to heed the following warnings while servicing the spark
  • Page 97 – PVT System; pinch; When To Use Low Range vs. High Range; Low Range
  • Page 98 – PVT Drying; the PVT system. Use the following instructions to dry it out before
  • Page 99 – Battery; Your ATV may have either a sealed battery, which requires little; Drink large quantities of water or milk. Follow with milk
  • Page 100 – Battery Removal; remove battery cover.; Battery Installation
  • Page 101 – Battery Storage; in an explosion and cause serious injury or death. When; fully charged
  • Page 102 – charged battery will register 12.8 V or higher.
  • Page 103 – Accessories; Washing the ATV; Waxing the ATV
  • Page 104 – Cleaning and Storage; Storage Tips; Starting the engine during the storage period will disturb the; Clean the Exterior
  • Page 105 – Fog the Engine; Do this carefully! If you miss the plug holes, oil will drain from
  • Page 106 – Inspect and Lubricate; Do not; Do not use plastic or coated materials. They do not allow
  • Page 107 – Transporting the ATV
  • Page 108 – ADJUSTMENTS; Camber and Caster
  • Page 109 – Throttle Body/Idle RPM; satisfactory, please see your Polaris dealer for adjustment.; Throttle Cable Freeplay; freeplay is achieved at the; While adjusting freeplay, be sure to flip the throttle lever back; they touch at the midpoint of the adjuster.
  • Page 110 – POLARIS PRODUCTS
  • Page 111 – TROUBLESHOOTING; solutions using the following charts.; Drive Belt and Cover Problems
  • Page 112 – Engine Doesn’t Turn Over
  • Page 113 – Engine Pings or Knocks
  • Page 114 – Engine Stops or Loses Power; Engine Overheating
  • Page 115 – SPECIFICATIONS
  • Page 116 – Clutching Chart; *EBS models require no helix / spring adjustment
  • Page 117 – WARRANTY; LIMITED WARRANTY
  • Page 119 – HOW TO OBTAIN WARRANTY SERVICE; Engine Oil; SPARK ARRESTOR
  • Page 120 – Exported Vehicles; How to Get Service; In the Country where your vehicle was purchased:
  • Page 121 – If Purchased From A Private Party:; Notice; chased, and you have not followed the procedure set out above, your
  • Page 123 – MAINTENANCE LOG; Use the following chart to record periodic maintenance.
  • Page 125 – INDEX
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Summary

Page 3 - to the owner’s manual on the next page. If you cannot locate this card,; The engine exhaust from this; WARNING

A card containing important ATV safety information should be attached to the owner’s manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance. The engine exhaust from this product contains chemicals known to cause cancer, birth def...

Page 4 - WELCOME; RANGER

1 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. S Snowmobiles S All-terrain vehicles (ATVs) S RANGER utility vehicles S Victory motorcycles We believe Polaris sets ...

Page 6 - TABLE OF CONTENTS

3 TABLE OF CONTENTS VEHICLE IDENTIFICATION NUMBERS 5 . . . . . . . SAFETY 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROLS 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERAT...

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